Cushion construction



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Patented Jan. 23, 1951 UNITED YSTATES CUSHION CONSTRUCTIGN Stephen J. Burns, Burbank, Calif.

Application September 16, l97ySerial`No.774,375

M'Claims. l

This invention relates to fabricated cushions, mattresses, pads, and the like, and particularly totypes of fabricated cushions, mattresses, and pads which are light in weight, flame-proof, buoyant, and especially resilient and suitable for use in aircraft and boats.

The use of rubber for cushions and mattresses is well-known, the present invention, however, being directed to a combination of air foam rubber and ber glass, the air foam rubber provid-- ing the shell to shape the cushion or mattress and also the cellular structure to aid in determining the resiliency over` predetermined areas. The iiber glass is used within the cells to control the resiliency by increasing or decreasing from normal the size or density of the rings or coils of ber glass within the cells. That is, the fiber glass is in the form of rolls and the tightness of the rolls withineaoh cell permits the resiliency :to be distributed as desired. Also, variations in size of the individual cells will control the density I The ber glass is .fire-proof, very buoyant, has no jelly action, and provides the maximum in vibration insulation between a vibrating seat or bed frame and the body of a person in a similar manner to the property of ber glass to absorb 'sound waves. This makes the structure particularly desirable for use in aircraft, trains, and the like.

The air foam rubber and fiber glass are so combined as to provide a pad in either cushion or mattress form which has the maximum of resiliency per pound of weight, which is particularly soft and body fitting while being flame-proof (foam-rubber will not burst into flame, but only melt, while fiber glass is nre-proof) which is Vsagproof, and which is particularly buoyant so as to serve as a life preserver in water. Its light Weight and extreme resiliency make it particularly desirable in aircraft where Weight is imiportant.

The principal object of the invention, therefore, is toprcvide an improved cushion, pad, or mattress construction.

Anotherobject of the invention is to provide a combination air foam rubber and iibergl'ass :cushion or pad.

Afurther object of the .invention is to `provide cushion of light weight, and one which is ameproof, buoyant, and in which the degree of resiliency may be controlled during construction.

A still further object of the invention isto provide a cushion or pad having a frame of air vfoam rubber and a'ller of rber glass.

A still further object of the invention is 'to provide 'a cellular structure of air foam rubber in 'which the cells are lled with rolls of liber glass of varying'tightness to control the resiliency fof the structure over predetermined areas.

"Although the novel features which are believed to be characteristic of this invention will be pointed out with particular-ity in the appended claims, the manner of its organization and the mode of its operation will be better understood by referring to the following description read` conjunction with the accompanying drawings, vfarming 'a part hereof, in which:

Fig. l shows perspective views of the cell and the filler therefor partially rolled.

Fig. 2 is an explode-d view of the shell or frame and cells of air foam rubber and the fillers of fiber glass.

Fig. 3 is a cross-sectional view of a completed cushion, pad, or mattress, embodying the invention.

Fig.. 4 is a cross-sectional view taken along the line li-4 of Fig. 3.

Fig.. 5 is a cross-sectional view of a modication of the invention.

Fig. 6 is a cross-sectional View taken along the Fig. `'7 is a cross-sectional view of the modification shown in Fig. 5 and taken along the line "J- of Fig. 5.

Referring now to the drawings, in which the same numerals refer to like elements, a shell or form is provided of air foam rubber, the top and bottom sheets li and t, respectively, being cut to the desired size, although the cushion shown in Figs. 1 4, inclusive, is reversible. These sheets may be of air foam rubber about one-fourth inch thick. This thickness lof rubber is also preferred -for the walls and cells of the average cushion, the thickness of the sheets being increased for larger units. The outer wall l is then cut to the desired height, this element forming three sides, the fourth side being a wall 8 'which is .cemented to the ends of wall l. These wall sections may be of different lengths, a preferred arrangement being shown. The edges of the wall sections are then cemented to the outer edge surface of the sheet The next units are the cylindrical cells lil formed by cutting air foam rubber into strips of the same width as the height of the walls 'l and 3 and cementing the ends together. These cells are then stacked o1' arranged 'within the Vwalls :and the bottom edges of 'the cells cemented to the 'slieett and y.each cell to each other, where they contact, and to the walls 'l and 8 where the outer cells contact the walls.

The next step in the construction is to ll the cells with coils of fiber glass. The fiber glass coils are made by cutting a sheet of fiber glass into strips which are rolled into coils I2, the tightness of the coils determining the density of the cushion. (See Fig. l.) The width of the ber glass strips or height of the coils is the same as the height of the cells lil, it being preferable to cement the ends of the coils to the sheet 6. The spaces between the cells l are lled with smaller rolls Il of fiber glass. The ber glass may be Owens-Corning Y-l3, or a similar quality fiberous product. Since the ber glass, as it comes off the conveyor at the manufacturers, has seventyfive percent of the fibers lying in one direction, these rolls are cut so that the majority of the bers will be on end when inserted in the cells, or at right angles to the base sheet 6. This arrangement provides maximum resiliency. Although the spaces between the cells I9 are shown filled only with ber glass rolls I l, small cells in which these rolls are inserted may be used in the spaces, although the small cells are not necessary.

The entire upper sheet is then covered with cement and placed over the walls l and 8, cells l0, and coils l2. By securing each fiber glass coil or roll in this mann-e1', additional help is given the roll to return to its normal shape by the tendency of the air foam rubber to return to its normal shape. By cementing the ends of the rolls, improved water-repellent qualities are given to the cushion. To further increase these qualities and to increase the seam strength, waterproof adhesive tape lll is secured at all seams.

For concentrated densities, such as bottom seat cushions, an additional base sheet of cored air foam rubber i6 (see Figs. 5, 6, and 7) having cores I 'l is cemented to an air foam rubber sheet 2E) which completely seals the cores Il, The air trapped in the cores prevents the cushion from having a bottcming eiect, the cores extending somewhat over one-half its depth into the base sheet l. The upper portion of the cushion is formed oi cells 2d and ber glass rolls 2l, as in Figs. 1-4, inclusive, except that a Waterfall is providedt the front edge of the cushion by a long ring 23 of air foam rubber filled with fiber glass 2li. The upper sheet 25 now extends over ring 23 to the bottom of base i5, all contacting surfaces being cemented together. The seams are covered by water-proof tape 26, the sides of the cushion havingr Walls such as shown at 28, 29, and 3S. Although the ber glass 2i.- is shown within an air foam cylinder 23, this unit may be solely of a roll of fiber glass. Furthermore, by using base sheets i 6 of dierent densities, various decrees of bottoining eiect may be obtained.

As foam rubber is porous, the air` is not cornpletely trapped, but escapes gradually and returns in the same manner. Sin-ce the 'oer glass coils are more effective when in close Contact with the body, any additional cushioning is placed under the coils i2 as shown in Figs. l to 4, inclusive, and under coils 2'!,fas shown in Figs. 5 7, inclusive. The entire cushion may be sprayed with a water-proof material to aid its buoyancy, while a quilted envelope of ber glass may be used for extreme fire prevention. The quilting is accomplished by sewing through and between the outer surfaces the same as quilting is done in cloth and cotton-lilled materials for bedding.

Cushions, pads, and mattresses constructed as described above do not sag, since each fiber glass core is individually secured to the base and cover of the shell and is restored by the resiliency of its individual cell and that of the cover and adjoining cells. By varying the tightness or number of turns of the cores, or nulnber of cells, a greater' density may be obtained at certain regions of the cushions such as at the front edge and decreasing toward the rear. The extreme buoyancy of the construction enhances their use as life-saving cushions. Although the shape of the cells I9 and 2S has been illustrated as Cylindrical, and this shape is preferred, other shapes may also be used, while the completed cushion or pad may have any desired sh pe.

I claim:

1. A cushion comprising a frame of bottom, top, and wall elements, a plurality of cellular units within said wall elements and having their ends attached to said bottom and top elements and their side contacting surfaces attached to each other and to said wall elements, and a plurality of iibrous coil elements rolled Within said units with the majority of the fibers extending parallel with the axis of said units and attached to said bottoni and top elements.

2. A cushion in accordance with claim l, in which said bottom, and wall elements and said cellular units are of air foam rubber and said coil elements are of er glass with long bers having th ends oi the bers contacting said bottom and top elements attached. thereto.

3. A cushion in accordance with claim l, in which said cushion is provided with a base element of cored air ioain rubber, said cores extending partially through said base clement, said bottom being cemented over the surface of said base having said cores to air seal said cores.

4. A cushion in accordance .i claim 1, in which a longitudinal coil is provided across one edge of said cushion.

5. A cushion construction comprising a frame having a side wall, and top bottom elements, a plurality or" hollow, cylindrical tubes Within said frame and attached to said wall, top and bottom elements, and to each other at points of contact, and rolled ber illers In said tubes and in the interstices between said tubes and said wall, top, and bottom elements, substantially seventy-five percent of the be s in said hilera being perpendicular to said top and bottom elements.

6. A cushion construction in accordance with claim 5, in which a base element is provided to which said bottom element is ttached.

7. A -cushion construction, comprising a frame having a side wall top and bottom elements, a plurality of cellular units Within said fran-ie and attached to said wall` top, and bottom elements, and to each otl at points of contact, and rolled liber fillers in said units and n the interstices between said units and said wall, top, and bottom elements, said wall, top, and 'bottom elements being of air foam rubber and said ber nllers being ber glass having the majority of the long bers extending parallel with the axis of said cellular units.

8. A cushion construction in accordance with claim 7, in which said wall, top, and base elements are covered with a Water-proof material.

9. A cushion construction comprising a bottoni` element, a plurality of cellular units having their ends attached to said bottom elements and their sides attached to each other at points of contact, rolled ber material within said units and in the interstices between said units and having the majority of the fibers thereof extending perpendicularly to the inner surface of said bottom element, a wall having its edge attached to the edge of said bottom element, and a top element having its edge attached to the other edge of said wall and to the other ends of said cellular units.

10. A cushion construction in accordance with claim 9, in which said cellular units are cylindrical and of sponge rubber and said rolled fiber material is ber glass, said rolls being of varying numbers of turns to vary the density over different portions of said cushion.

11. A cushion construction of substantially rectangular shape comprising a Wall having a width of substantially the thickness of said cushion, a ilat bottom element attached to one of the edges of said Wall, a plurality of hollow cylindrical cells stacked side by side Within the boundaries of said wall and having one end of each cell attached to said bottom element, a plurality of rolls, one each of which is within one of said cells, said rolls having their ends attached to said bottom element, and a top element similar to said bottom element and which is attached to the other 'edge of said Wall and to the other ends of said cells and rolls, said wall, top and bottom elements, and said cells being of air foam rubber and said rolls being of ber glass of dif,- ferent numbers of turns to vary the density of said cushion over different areas and having` the majority of the fibers extended perpendicularly to the top and bottom elements.

l2. A cushion construction of substantially rectangular shape, lcomprising a wall having a width of substantially the thickness of said cushion and extending along three sides of said cushion, a nat, bottom element, a plurality of hollow cylindrical cells stacked side by side within the boundarles of said wall and having one end of each cell attached to said bottom element, a plurality of rolls, one each of which is within one of said cells, said rolls having their ends attached to said bottom element, a top element attached to the other edge of said Wall and to the other ends of said cells and rolls, a cored air foam base attached to the underside of said bottom element and a fiber glass roller extending longitudinally between two sides of said Wall and between said bottom and top ele-ments, said top element extending over said roller and to the bottomof said base.

13. A cushion construction in accordance with claim 12, in which said rolls are of liber glass having the major portion of the long fibers parallel With the longitudinal axis of said cells.

14. A cushion comprising a top element, a bottom element, said top and bottom elements being parallel to one another and of air foam rubber, a plurality of cells between the top and bottom surfaces of said elements, the axes of said cells being perpendicular to the surfaces of said top and bottom elements, and a fiber glass roll in each o1" said cells having the majority of the individual bers thereof perpendicular to the top and bottom surfaces of said elements.

STEPHEN J. BURNS.

REFERENCES CITED The `following references are of record ln the le of this patent:

UNITED STATES PATENTS Number Name Date 139,202 Smith May 20, 1873 698,529 Marshall Apr.r29, 1902 880,784 Ferres Mar. 3, 1908 1,192,510 Fischman July 25, 1916 1,296,359 Brown Mar. 4, 1919 1,579,074 Burton Mar. 30, 1926 1,980,445 Sherover Nov. 13, 1934 2,271,842 Nachman Feb. 3, 1942 FOREIGN PATENTS Number Country Date 482,809 Great Britain Apr. 4, 1938 747,776 France Apr. 4, 1933 

